Oral care products and methods of using and making the same

ABSTRACT

An oral care implement may include a base portion sized for insertion into an oral cavity and a plurality of flexible, elastomeric elements extending from the base portion, wherein each of the plurality of flexible, elastomeric elements comprises an edge, wherein at least one of the edges comprises a micro edge, and wherein the plurality of flexible, elastomeric elements comprises an element density of less than about 5 mm. Another embodiment of an oral care implement may include a base portion sized for insertion into an oral cavity and a plurality of flexible, elastomeric elements extending from the base portion, wherein at least one of the plurality of flexible, elastomeric elements comprises a first section having a first section edge and a first transverse cross sectional area, and a second section disposed adjacent to the first section along a longitudinal axis of the at least one of the plurality of flexible, elastomeric elements, the second section having a second section edge and a second transverse cross sectional area different from the first transverse cross sectional area. Yet another embodiment of an oral care implement includes a base portion sized for insertion into an oral cavity, the base portion having a base wall and two opposed, side walls connected to the base wall that form a channel for receiving teeth within an oral cavity and a plurality of flexible, elastomeric elements extending into the channel from the base and two opposed, side walls.

FIELD OF THE INVENTION

The present invention relates to Oral care cleaning implements, devices,and systems having flexible elements, particularly flexible, elastomericelements, and methods of using and making the same.

BACKGROUND OF THE INVENTION

Although many innovations have been made in the field of oral healthcare, there is a continuing need for oral care products and methodswhich can improve the health and appearance of the oral cavity andteeth, such as teeth cleaning, teeth whitening, and plaque removal.

SUMMARY OF THE INVENTION

The several embodiments presented herein are directed to oral caresystems and/or oral care implements comprising a base and a plurality offlexible, elastomeric elements, and methods of using and making thesame.

One embodiment may comprise an oral care implement that includes, atleast in part, a base portion sized for insertion into an oral cavity aplurality of flexible, elastomeric elements extending from the baseportion, wherein each of the plurality of flexible, elastomeric elementscomprises an edge, at least one of the edges comprises a micro edge, andthe plurality of flexible, elastomeric elements comprises an elementdensity of less than about 5 mm.

Another embodiment may comprise an oral care implement that includes, atleast in part, a base portion sized for insertion into an oral cavityand a plurality of flexible, elastomeric elements extending from thebase portion, wherein at least one of the plurality of flexible,elastomeric elements comprises a first section having a first sectionedge and a first transverse cross sectional area, and wherein a secondsection disposed adjacent to the first section along a longitudinal axisof the at least one of the plurality of flexible, elastomeric elements.The second section includes a second section edge and a secondtransverse cross sectional area different from the first transversecross sectional area.

Yet another embodiment may comprise an oral care implement thatincludes, at least in part, a base portion sized for insertion into anoral cavity, the base portion having a base wall and two opposed, sidewalls connected to the base wall that form a channel for receiving teethwithin an oral cavity, and a plurality of flexible, elastomeric elementsextending into the channel from the base and two opposed, side walls.Each of the plurality of flexible, elastomeric elements comprises anedge and a longitudinal axis, wherein at least one of the plurality offlexible, elastomeric elements comprises a first section having a firsttransverse cross sectional area and a second section having a secondtransverse cross sectional area that is disposed adjacent to the firstsection along the longitudinal axis of the at least one flexible,elastomeric element, and wherein the second transverse cross sectionalarea is different than the first transverse cross sectional area.

Still yet another embodiment may comprise a method of forming a microedge of an flexible, elastomeric element. The method may include thesteps of forming a mold cavity with a first mold plate and a second moldplate positioned adjacent to the first mold plate, forming a mold cornerof the mold cavity using an intersection of the first mold plate andsecond mold plate, injecting an elastomer into the mold cavity, andallowing gas contained within the mold cavity to out-gas through theintersection between the first and second mold plates to form a microedge along the mold corner formed by the intersection.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed the same will bebetter understood from the following description taken in conjunctionwith the accompanying drawings in which:

FIG. 1A is a perspective view of an oral care implement;

FIG. 1B is a detail of a top planar view of a flexible, elastomericelement of FIG. 1A;

FIG. 2A is a top planar view of another embodiment of a flexible,elastomeric element;

FIG. 2B is a top planar view of another embodiment of a flexible,elastomeric element;

FIG. 2C is a top planar view of another embodiment of a flexible,elastomeric element;

FIG. 2D is a top planar view of another embodiment of a flexible,elastomeric element;

FIG. 2E is a top planar view of another embodiment of a flexible,elastomeric element;

FIG. 3 is a partial perspective view of another embodiment of an oralcare implement;

FIG. 4 is a perspective view of a flexible, elastomeric element of theoral care implement of FIG. 3;

FIG. 5 is a side elevational view of the flexible, elastomeric elementof FIG. 4;

FIG. 6 is a top planar view of the flexible, elastomeric element of FIG.4;

FIG. 7 is a detail of a top planar view of the flexible, elastomericelement of FIG. 5;

FIG. 8 is a detail of the flexible, elastomeric element of FIG. 6;

FIG. 9 is a perspective view of another embodiment of a flexible,elastomeric element;

FIG. 10 is a side elevational view of the flexible, elastomeric elementof FIG. 9;

FIG. 11 is a top planar view of the flexible, elastomeric element ofFIG. 9;

FIG. 12 is an exploded, perspective view of an embodiment of a moldsystem in combination with a mold machine;

FIG. 13 is a perspective view of another embodiment of a flexible,elastomeric element fabricated from the mold system of FIG. 12;

FIG. 14 is a partial cross sectional view of the mold system of FIG. 12;

FIG. 15A is a an exploded, perspective view of another embodiment of amold system;

FIG. 15B is a partial perspective view of the mold system of FIG. 15A;

FIG. 16 is a perspective view of another embodiment of a flexible,elastomeric element fabricated from the mold system of FIG. 15A;

FIG. 17 is a perspective view of another embodiment of a mold system;

FIG. 18 is a perspective view of another embodiment of a flexible,elastomeric element fabricated from the mold system of FIG. 17;

FIG. 19A is a detail of the mold system of FIG. 17;

FIG. 19B is a detail of the mold system of FIG. 17;

FIG. 20 is a partial perspective view of another embodiment of a moldsystem;

FIG. 21 is a partial cross sectional view of an embodiment of a cavitymold plate of the mold system of FIG. 20;

FIG. 22 is a schematic representation of an embodiment of an oral caresystem;

FIG. 23 is a schematic representation of another embodiment of an oralcare implement;

FIG. 24A is a schematic representation of a top perspective view ofanother embodiment of a plurality of flexible, elastomeric elements;

FIG. 24B is a schematic representation of an isometric view of theplurality of flexible, elastomeric elements of FIG. 24A moving into aninterdental area of an oral cavity before engagement with any teethsurfaces within the interdental area;

FIG. 24C is a schematic representation of an isometric view of theplurality of flexible, elastomeric elements of FIG. 24A moving into andengaging the interdental area;

FIG. 24D is a schematic representation of a top perspective view of theplurality of flexible, elastomeric elements of FIG. 24C, illustratingthe initial twisting, bending, and/or deformation of the plurality offlexible, elastomeric elements;

FIG. 24E is a schematic representation of an isometric view of theplurality of flexible, elastomeric elements of FIG. 24D moving furtherinto and engaging the interdental area; and

FIG. 24F is a schematic representation of a top perspective view of theplurality of flexible, elastomeric elements of FIG. 24E, illustratingthe twisting, bending, and/or deformation of the plurality of flexible,elastomeric elements and contact stresses due to the engagement with theinterdental area.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, “an edge” is a line at which two surfaces intersect, ora border at which a surface terminates.

“Include” and its variants are non-limiting in the sense that recitationof items “included” in a list does not exclude other items.

As used herein, a “micro” edge is an edge as defined herein that isfabricated to have a tip radius (R) of less than 0.0254 mm, particularlyless than or equal to about 0.02 mm, more particularly less than orequal to about 0.015 mm, more particularly less than or equal to about0.01 mm, more particularly less than or equal to about 0.008 mm, moreparticularly less than or equal to about 0.0075 mm, more particularlyless than or equal to about 0.007 mm, more particularly less than orequal to about 0.0065 mm, more particularly less than or equal to about0.006 mm, more particularly less than or equal to about 0.0055 mm, moreparticularly less than or equal to about 0.005 mm, more particularlyless than or equal to about 0.0045 mm, more particularly less than orequal to about 0.004 mm, more particularly less than or equal to about0.0035 mm, more particularly less than or equal to about 0.003 mm, moreparticularly less than or equal to about 0.0025 mm, more particularlyless than or equal to about 0.002 mm, more particularly less than orequal to about 0.0015 mm, more particularly less than or equal to about0.001 mm, and/or from about 0.0254 mm to about 0.001 mm, from about to0.02 mm to about 0.001 mm, particularly from about 0.015 mm to about0.0015 mm, particularly from about 0.01 mm to about 0.002 mm, moreparticularly from about 0.009 mm to about 0.0025 mm, more particularlyfrom about 0.0085 mm to about 0.0025 mm, and/or more particularly fromabout 0.008 mm to about 0.0025 mm. One example of a micro edge comprisesan out-gassed edge. As used herein, “an out-gassed” edge is an edge, asdefined herein, formed by the out-gassing between two cavity mold plates(at the point of engagement between the two cavity mold plates) from amold cavity used in a molding process such as plastic injection molding.The molding plates are used to form at least a portion of a mold cavityto form an element (e.g., element 10). During the molding process, gasin the mold cavity out-gasses through and between the space locatedwhere the two molding plates engage one another (i.e., intersection ofthe two molding plates), thus pushing and/or pulling the material (e.g.,plastic) deep into the corner of the mold cavity formed by theintersection of the two molding plates. When the plastic penetrates intothe corner of the mold cavity by the out-gassing process, it forms amicro edge (e.g., micro edge 18) along the flexible element (e.g.,element 10).

“Oral care composition” or “oral composition” means a product which inthe ordinary course of usage can be retained in the oral cavity forcontacting selected dental surfaces and/or oral tissues for purposes oforal activity. In addition to cleaning teeth to remove dental plaque,oral care compositions may be used to prevent formation of dentalcalculus and disorders such as caries, periodontitis and gingivitis, andalso to eliminate and prevent oral malodor or halitosis and staining.Some examples of oral care product forms are toothpastes, dentifrices,tooth gels, subgingival gels, foams, mouth rinses, denture products,mouth sprays, lozenges, chewable tablets or chewing gums and strips orfilms for direct application or attachment to oral surfaces includingany hard or soft oral tissues.

As used herein, “oral cavity” means a cavity comprising oral cavitytissue as defined herein, including but not limited to human mouthsand/or mouths of other animals.

As used herein, “oral cavity tissue” means any hard or soft tissuedisposed within the oral cavity such as teeth and gum tissue.

As used herein, the terms “oral condition” and “condition” are used torefer to dental plaque, tartar, debris, tooth decay, bio films, softtissue abnormalities, soft tissue lesions, etc. within the oral cavity.

“Orally acceptable additive” means any additive which is now known, orhereinafter becomes known, as a safe and effective additive for an oralcare composition. Examples include conventional additives in oral carecompositions including but not limited to fluoride ion sources,anti-calculus or anti-tartar agents, desensitizing agents, teethwhitening agents such as peroxide sources, abrasives such as silica,herbal agents, chelating agents, buffers, anti-staining agents, alkalimetal bicarbonate salts, thickening materials, humectants, water,surfactants, titanium dioxide, flavor system, sweetening agents,xylitol, coloring agents, and mixtures thereof.

As used herein, the terms “plaque” and “dental plaque” are used to referto a bio-film that builds up on teeth, on gingival tissue, oral hardtissue, and/or oral soft tissue.

“Plaque bacteria” means bacteria that causes plaque to form.

“Teeth” refers to one or more natural teeth as well as one or moreartificial teeth or dental prosthesis.

Referring to FIGS. 1-24, several embodiments of flexible elements (e.g.,flexible elements 10, 50, 150, 155, etc.), oral care implements (e.g.,implements 1, 20, 2000, etc.) including such elements, and methods ofmaking and using the same are shown. Not to be limited by theory, it hasbeen discovered that the manipulation of certain, but not all, elementand/or oral care implement properties provide improved oral carecleaning benefits, including but not limited to reduced cleaning times,increased contact stress, increased contact traces, and plaque removal.One or more of the following flexible element properties: size, crosssectional shape, length, material properties (e.g., hardness(durometer), surface friction, etc.), distance from the oral care tissue(e.g., teeth, gums, etc.), driving motion (i.e., motion initiated on theflexible elements for cleaning of the oral care tissue), and/or edgeproperties, including but not limited to edge tip radius, number,location, orientation, and hardness/stiffness, may be manipulated ormaximized to provide surprisingly improved cleaning of oral care tissuesuch as, for example, cleaning within interdental areas (i.e., betweenthe teeth). In addition, it has been discovered that the density offlexible elements along an oral care implement that includes suchflexible elements when combined with one or more of the flexible elementproperties set forth above may be maximized to provide improved oroptimized cleaning of oral care tissue.

As one example, it has been discovered that manipulating one or more ofthe element and/or oral care implement properties set forth above impactthe contact trace (i.e., the path along a tooth's surface that an edge(cleaning edge) of a flexible element contacts the tooth during thecleaning motion). As such, and not to be limited by theory, with theright combination of properties, it has been discovered that the contacttrace of one or more of the flexible elements of an oral care elementmay be controlled, improved, and/or increased, particularly within theinterdental areas, and thus improve the cleaning capabilities of suchoral care element(s) and/or implement such as, for example, improvedinterdental cleaning.

Again, not to be limited by theory, it has been discovered that thecontact stress (i.e., the component of the applied force of the flexibleelement which is normal to the surface of the oral care tissue (tooth orgums) at the point where the edge contacts the oral care tissue dividedby the contact area between the edge of the flexible element and theoral care tissue) of one or more of the flexible elements of an oralcare implement may be controlled, improved, and/or increased bymanipulating the element's edge tip radius, length, spacing withadjacent elements (element density), hardness (durometer), and/orsurface friction. It has been discovered that an improved cleaningedge/element configuration can produce high contact stresses over largecontact traces (tooth surface areas) for particular cleaning motions.

The several embodiments shown and described herein are examples offlexible elements and/or oral care cleaning implements that provide suchimproved oral cleaning benefits.

Referring to FIG. 1 a, an embodiment of an oral care implement 1 isshown, comprising, in part, a base 20 and a plurality of elements 10extending from the base 20. Each element 10 may comprise a distal end12, a proximal end 14 opposite of the distal end 12, a longitudinal axisA-A′, and a transverse surface 16 that is disposed transverse to thelongitudinal axis A-A′. It is understood that in an element having adifferent transverse cross sectional shape than element 10 shown in FIG.1A, the edge 18, rather than being a transverse edge, may be alongitudinal edge, i.e., disposed substantially along the longitudinalaxis A-A′. In the embodiment shown, the base 20 and the plurality ofelements 10 are fabricated as one integrated unit. It is understood thatthe base 20 and the plurality of elements 10 may be two separatecomponents that are connected together using conventional techniques andmethods of connection such as, for example, adhesives, knotting, sonicwelding, etc.

The oral care implement 1 may comprise an implement density of theplurality of elements 10, which comprises the spacing between eachadjacent element 10. As such, the element density may be measured bymeasuring the distance (d) between a center point of one element 10 to acenter point of an adjacent element 10. The base 20 and the plurality ofelements 10 may be fabricated such that the elements 10 are equallyspaced from each other. In another embodiment, the base 20 and theplurality of elements 10 may be fabricated such that the individualelements are unequally separated from each other along the base 20. Insuch an embodiment, the element density is an average of the measureddistances between each element 10. In one embodiment, the base 20 has anelement density from about 0.05 mm to about 5.0 mm, more particularlyfrom about 0.1 mm to about 3.0 mm, or more particularly from about 0.1to about 2 mm. Although the base 20 is shown in FIG. 1A as having acircular shape, it is understood that the base 20 may comprise otherconfigurations, sizes, and shapes, including but not limited topolygon-shaped, elliptical-shaped, U-shaped, U-shaped forming a channel,and other configurations operable to insert into an oral cavity andenable the plurality of bristles to engage the oral cavity tissuestherein.

FIG. 1A shows each element 10 having a transverse cross sectional areathat remains constant from the proximal end 14 to the distal end 12. Inanother embodiment, each element 10 may taper inwardly toward thelongitudinal axis A-A′ from the proximal end 14 to the distal end 12. Assuch, the cross sectional area of the element 10 transverse to thelongitudinal axis A-A′ (“transverse cross sectional area”) at theproximal end 14 is larger than the transverse cross sectional area atthe distal end 12. Alternatively, each element 10 may taper outwardlyaway from the longitudinal axis A-A′ from the proximal end 14 to thedistal end 12. As such, the transverse cross sectional area of theelement 10 at the proximal end 14 is smaller than the transverse crosssectional area at the distal end 12. In yet another embodiment, the oralcare implement 1 may comprise a plurality of elements having constanttransverse cross sections, inwardly tapering transverse cross sections,outwardly tapering transverse cross sections, or any combinationthereof.

As shown in FIG. 1A, the plurality of elements 10 have a roundtransverse cross sectional shape. As such, the elements 10 shown in FIG.1A, only comprise one edge 18 that is transverse to the longitudinalaxis A-A′ (“transverse edge”). The edge 18 is disposed at theintersection of transverse surface 16 and side surface 15. FIG. 1B showsthe edge 18 having a tip radius (r). In one embodiment, one or more ofthe plurality of elements 10 may be fabricated using the plasticinjection method and mold system described below herein such that theedge 18 is a micro edge, wherein the micro edge has a tip radius (r) asdefined above herein. Until the discovery of the method and mold systemshown and described herein, it was not possible to injection moldplastic, such as an elastomeric material, into mold cavity cornerssufficient enough to fabricate micro edges as defined herein.

In another embodiment, the edge 18 may comprise a tip radius (r) havingany conventional value. In yet another embodiment, the edge 18 maycomprise a tip radius as shown and described in U.S. Pat. Pub. No.2009/0007357, and herein incorporated by reference.

In other embodiments, the elements 10 may comprise a transversecross-section having a variety shapes, sizes, and configurations,including but not limited to circular-shaped as shown in FIG. 1A,oval-shaped as shown in FIG. 2A, elliptical-shaped, polygonal-shaped(not shown), tetrahedron-shaped (not shown), square-shaped FIG. 2B,rectangle-shaped (FIG. 2B), star-shaped as shown in FIG. 2C,cross-shaped as shown in FIG. 2D, triangle-shaped as shown in FIG. 2E,sinusoidal-shaped (not shown), other conventional shaped configurations,and/or combinations thereof. In addition, the element 10 may have asingle, continuous transverse cross sectional area and shape as shown,for example, in FIG. 1A. Alternatively, the element may include one ormore segments, wherein each segment may have a different transversecross sectional area and/or shape as shown, for example, in FIGS. 3 and9. The shape of the transverse cross-section of the element may bedetermined based upon the number of edges and/or flat surfaces desired.

As shown in FIGS. 2B, 2C, 2D, and 2E, the element 10 may comprise one ormore transverse edges 18 and one or more edges 19 that are disposedsubstantially along the longitudinal axis A-A′ (“longitudinal axis”). Inthe alternative embodiments shown in FIGS. 2B, 2C, 2D, and 2E, theelements 10 may be fabricated such that one or more of the transverseedges 18, longitudinal edges 19, or a combination of the two maycomprise a micro edge, wherein the micro edge has a tip radius (r) asdefined above herein. Alternatively, in the embodiments shown in FIGS.2B, 2C, 2D, and 2E, the elements 10 may be fabricated such that one ormore of the transverse edges 18, longitudinal edges 19, or a combinationof the two may comprise a conventional edge tip radius as shown anddescribed in U.S. Pat. Pub. No. 2009/0007357, and herein incorporated byreference. Also, the embodiments shown in FIGS. 2B, 2C, 2D, and 2E, theelements 10 may be fabricated such that one or more of the transverseedges 18, longitudinal edges 19, or a combination of the two may includesome mixture of both micro edges and conventional edges.

Referring to FIGS. 3-8, another embodiment of an oral care implement 40is shown. The oral care implement 40 comprises a base 100 and aplurality of elements 50 extending from the base 100. The elements 50comprise a proximal end 54 connected to the base 100 and a distal end 52opposite the proximal end. As shown, the elements 50 may comprise foursegments: a first segment 60 at the distal end 52; a second segment 70disposed at an end of the first segment 60 opposite the distal end 52; athird segment 80 disposed at an end of the second segment 70 oppositethe first segment; and a fourth segment 90 disposed at an end of thethird segment 80 opposite the second segment. In is understood that theelements 50 may comprise any number of segment, including but notlimited to one, two, three, or any other number. The segments may befabricated such that the segments are integral to each other such as,for example integrally formed using a plastic injection molding process.In another embodiment, each segment may be fabricated as separatecomponents that then are attached to adjacent segments usingconventional connection techniques or devices, including but not limitedto welding, adhesives, snap-fit connections, etc.

In the embodiment shown, the base 100 and the plurality of elements 50are fabricated as one integrated unit to form, at least in part, theoral care implement 40. It is understood that the base 100 and theplurality of elements 50 may be two separate components that areconnected together using conventional techniques and methods ofconnection such as, for example, adhesives, knotting, sonic welding,etc.

Referring particularly to FIGS. 4, 5, and 6, the elements 50 in thisembodiment comprise a triangular-shaped transverse cross section. Assuch, the first segment 60 comprises a transverse surface 61, threelongitudinal surfaces 63, a transverse edge 66, a first longitudinaledge 68 a, second longitudinal edge 68 b, and a third longitudinal edge68 c. Additionally, the second segment 70 comprises a transverse surface71, three longitudinal surfaces 73, a transverse edge 76, a firstlongitudinal edge 78 a, second longitudinal edge 78 b, and a thirdlongitudinal edge 78 c. Also, the third segment 80 comprises atransverse surface 81, three longitudinal surfaces 83, a transverse edge86, a first longitudinal edge 88 a, second longitudinal edge 88 b, and athird longitudinal edge 88 c. Also, the fourth segment 90 comprises atransverse surface 91, three longitudinal surfaces 93, a transverse edge96, a first longitudinal edge 98 a, second longitudinal edge 98 b, and athird longitudinal edge 98 c.

FIG. 7 shows the transverse edge 66 having a tip radius (r). Thetransverse edges 76, 86, and 96 may also comprise a tip radius as shownand measured in FIG. 7. In one embodiment, the element 50 may includeone or more transverse edges 66, 76, 86, and/or 96 that comprise a microedge as defined above herein. In another embodiment, the element 50 mayinclude one or more transverse edges 66, 76, 86, and/or 96 that maycomprise a conventional edge tip radius as shown and described in U.S.Pat. Pub. No. 2009/0007357, and herein incorporated by reference. It isunderstood that the oral care implement 40 may be fabricated such thatnone of the elements 50 comprise a micro, transverse edge or all theelements 50 have at least one micro, transverse edge.

FIG. 8 shows the longitudinal edge 88 c having a tip radius (r). Thelongitudinal edges 68 a, 68 b, 68 c, 78 a, 78 b, 78 c, 88 a, 88 b, 98 a,98 b, and 98 c may also comprise a tip radius (r) as shown and measuredin FIG. 8. In one embodiment, the element 50 may comprise one or morelongitudinal edges 68 a, 68 b, 68 c, 78 a, 78 b, 78 c, 88 a, 88 b, 88 c,98 a, 98 b, and/or 98 c that comprise a micro edge as defined herein. Inanother embodiment, the element 50 may comprise one or more longitudinaledges 68 a, 68 b, 68 c, 78 a, 78 b, 78 c, 88 a, 88 b, 88 c, 98 a, 98 b,and/or 98 c that comprise a conventional edge tip radius as shown anddescribed in U.S. Pat. Pub. No. 2009/0007357, and herein incorporated byreference. It is understood that the oral care implement 40 may befabricated such that none of the elements 50 comprise a micro,longitudinal edge or all the elements 50 have at least one micro,longitudinal edge.

Referring back to FIG. 5, the element 50 comprises a length (L). Length(L) may comprise from about 0.05 mm to about 10 mm, particularly fromabout 0.1 mm to about 8 mm, more particularly from about 1.0 mm to about7 mm, or more particularly from about 2.0 mm to about 6 mm. In oneembodiment, the length (L) of the element 50 may comprise about 4 mm.Each of the first, second, third, and fourth segments 60, 70, 80 and 90may comprise any length as desired. In addition, the first segment 60may have a first segment width (W₁) from about 0.06 to about 1.0 mm, asegment width (W₂) from about 0.07 mm to about 2.0 mm, a third segmentwidth (W₃) from about 0.09 mm to about 3.0 mm, and a fourth width (W₄)from 0.1 mm to about 4.0 mm.

One or more of the longitudinal surfaces 63, 73, 83, and 93 may beoriented at an angle α relative to an imaginary vertical plane (e.g.,vertical plane M shown in FIG. 5). The angle α may less than about 30degrees, particularly less than about 20 degrees, more particularly lessthan about 15 degrees, more particularly less than about 10 degrees,even more particularly less than about 5 degrees, and/or from about 0degrees to about 90 degrees, from about 15 degrees to about 75 degrees,particularly from about 30 degrees to about 60 degrees, moreparticularly from about 0 degrees to about 45 degrees, even moreparticularly from about 0 degrees to about 30 degrees, even moreparticularly from about 0 degrees to about 15 degrees, even still moreparticularly from about 0 degrees to about 10 degrees, or even stillmore particularly about 1.5 degrees.

The oral care implement 40 may comprise an element density of theplurality of elements 50, which comprises the spacing between eachadjacent element 50. As such, the element density may be measured bymeasuring the distance (d) between a center point of one element 50 to acenter point of an adjacent element 50. The base 100 and the pluralityof elements 50 may be fabricated such that the elements 50 are equallyspaced from each other. In another embodiment, the base 100 and theplurality of elements 50 may be fabricated such that the individualelements are unequally separated from each other along the base 100. Insuch an embodiment, the element density is an average of the measureddistances between each element 50. In one embodiment, the base 100 hasan element density from 0.09 mm to about 0.4 mm, more particularly fromabout 0.1 mm to about 3.0 mm, or more particularly from about 0.2 mm toabout 2 mm.

Referring to FIGS. 9-11, another embodiment of an element for an oralcare implement (not shown but may be the same as or similar to thoseoral care implements shown and described herein, e.g., oral careimplements 1, 40) is shown as 150. The element 150 may a proximal end154 and a distal end 152 opposite of the proximal end 154. As in otherembodiments shown and described herein, the element 150 may extend froma base (not shown), wherein the proximal end 154 is integral with orconnected to the base. As also in the other embodiments, a plurality ofelements 150 may extend from the base to form, in part, an oral careimplement.

As shown, the element 150 may comprise three segments: a first segment160 at the distal end 152; a second segment 170 disposed at an end ofthe first segment 160 opposite the distal end 152; a third segment 180disposed at an end of the second segment 170 opposite the first segment160. As set forth above with reference to the other embodiments, theelement 150 may comprise any number of segment, each having any numberof shapes, sizes, and configurations. As with the element's connectionwith the base, the segments (e.g., first, second, and third segment 160,170, and 180) may be fabricated such that the segments are integral toeach other such as, for example integrally formed using a plasticinjection molding process. In another embodiment, each segment may befabricated as separate components which then may be attached to adjacentsegments using conventional connection techniques or methods, includingbut not limited to welding, adhesives, knotting, snap-fit connections,etc.

The first segment 160 may comprise a star-shaped transverse crosssection as shown in FIGS. 9 and 11. The first segment 160 comprises atransverse surface 166, ten longitudinal surfaces 163, ten transverseedges 166 a-j (traversing about the longitudinal axis A-A′ of the firstsegment in a counter clockwise direction), and ten longitudinal edge 168a-j (traversing about the longitudinal axis A-A′ of the first segment ina counter clockwise direction). The second segment 170 may comprise asquare-shaped transverse cross section. The second segment 170 comprisesa transverse surface 171, four longitudinal surfaces 173, fourtransverse edges 176 a-d (traversing about the longitudinal axis A-A′ ofthe second segment in a counter clockwise direction), and fourlongitudinal edges 178 a-d. The third segment 180 may comprise across-shaped transverse cross section. The third segment 180 comprises atransverse surface 181, twelve longitudinal surfaces 183, twelvetransverse edges 186 a-l (traversing about the longitudinal axis A-A′ ofthe third segment in a counter clockwise direction), and eightlongitudinal edges 188 a-h. The transverse edges 166 a-j, 176 a-d, and186 a-l and longitudinal edges 168 a-e, 178 a-d, and 188 a-h ofimplement 150 may comprise a tip radius (r) such as, for example, thetip radius shown and measured in FIGS. 7 and 8.

In the embodiment shown in FIGS. 9-11, the first segment 160, secondsegment 170, and third segment 180, each have a transverse crosssectional area that is different from the other segments' transversecross sectional area. Specifically, the first segment's transverse crosssection area is smaller than the second and third segments' transversecross sectional areas, and the second segment's transverse crosssectional area is smaller than the third segment's transverse crosssectional area, giving the element 150 a tiered configuration. It isalso understood that the longitudinal edges of the first, second, and/orthird segments may be oriented at any angle (e.g., angle α as shown inFIG. 5) relative to the longitudinal axis. The angle α may less thanabout 30 degrees, particularly less than about 20 degrees, moreparticularly less than about 15 degrees, more particularly less thanabout 10 degrees, even more particularly less than about 5 degrees,and/or from about 0 degrees to about 90 degrees, from about 15 degreesto about 75 degrees, particularly from about 30 degrees to about 60degrees, more particularly from about 0 degrees to about 45 degrees,even more particularly from about 0 degrees to about 30 degrees, evenmore particularly from about 0 degrees to about 15 degrees, even stillmore particularly from about 0 degrees to about 10 degrees, or evenstill more particularly about 0 degrees.

Referring to FIG. 10, the element 150 comprises a length (L). Length (L)may comprise from about 0.5 mm to about 10 mm, particularly from about1.0 mm to about 8 mm, more particularly from about 2.0 mm to about 7 mm,or more particularly from about 3.0 mm to about 6 mm. In one embodiment,the length (L) of the element 150 may comprise about 4 mm. Each of thefirst, second, and third segments 160, 170, and 180 may comprise anylength as desired. In addition, the first segment 60 may have a firstsegment width (W₁) from about 0.06 mm to about 1.0 mm, a segment width(W₂) from about 0.07 mm to about 2.0 mm, and a third segment width (W₃)from about 0.09 mm to about 3.0 mm. The width as used herein maycomprise the longest dimension along the transverse cross section. Aswith the length, the segments of element 150 may comprise any width asdesired.

The oral care implement may comprise an implement density of theplurality of elements 150, which comprises the spacing between eachadjacent element 150. As such, the element density may be measured bymeasuring the distance between a center point of one element 150 to acenter point of an adjacent element 150. The base and the plurality ofelements 150 may be fabricated such that the elements 150 are equallyspaced from each other. In another embodiment, the base and theplurality of elements 150 may be fabricated such that the individualelements are unequally separated from each other along the base. In suchan embodiment, the element density is an average of the measureddistances between each element 150. In one embodiment, the base has anelement density from 0.09 mm to about 0.4 mm, more particularly fromabout 0.1 mm to about 3.0 mm, or more particularly from about 0.2 mm toabout 2 mm.

In one embodiment, one or more of the transverse edges (e.g., transverseedges 166 a-j, 176 a-d, and 186 a-l of the element 150 may comprise amicro edge. In another embodiment, one or more of the longitudinal edges168 a-e, 178 a-d, and 188 a-h of element 150 may comprise a micro edge.In yet another embodiment, the element 150 may comprise the transverseedges 166 a-j, 176 a-d, and 186 a-l and longitudinal edges 168 a-e, 178a-d, and 188 a-h, wherein at least one of the traverse edges and atleast one of the longitudinal edges are micro edges, edges, orcombinations thereof.

An oral care implement (e.g., oral care implement 1 of FIG. 1) maycomprise a plurality of element such as, for example, element 150, or acombination of elements such as, for example, elements 50, or otherconventional or yet-to-be developed elements. The several examples ofthe elements (e.g., 10, 50, 150, 2050) and bases (e.g., 20, 100, 2100)shown and described herein may be fabricated from a variety ofmaterials, particularly materials used for oral care applications suchas, for example materials used for oral care bristles, flexibleelements, etc. In one embodiment, the elements (e.g., 10, 50, 150, 2050)are fabricated from a compliant material for enhanced cleaning withreduced abrasion. The bases (e.g., 20, 100, 2100) may be fabricated fromthe same or different material as the elements depending upon theproperties desired. Also, the material used for the fabrication of theelements and/or the bases may be a single substrate material, compositematerial, multi-laminate structure, or any combination thereof.

In one or more of the embodiments shown and described herein, thematerial used for the elements (e.g., 10, 50, 150, 2050) and/or bases(e.g., 20, 100, 2100) may comprise a flexible (or compliant) material,including but not limited to thermoplastic elastomers, rubber, flexiblecomposites, and combinations thereof. In an embodiment, one or more ofthe plurality of elements (e.g., 10, 50, 150, 2050) and/or bases (e.g.,20, 100, 2100) may be formed of a thermoplastic or a cross-linkedmaterial (a thermoset material).

Examples of suitable elastomeric materials include one or more styreniccopolymers, thermoplastic polyurethanes, silicones, polyether-amides,polyether-polyesters, or mixtures of these and other elastomers. Anyelastomeric material described herein can include one or more fillers.For example, the filler may be or may include oil, e.g., mineral oils,abrasives, tackifiers, plasticizers or mixtures of these and evenothers. As an example, the material that may be used for one or more ofthe plurality of element (e.g., 10, 50, 150, 2050) and/or bases (e.g.,20, 100, 2100) may comprise a flexible material having a Shore Hardnessof from about 8 Shore A to about 75 Shore D, as a further example, fromabout 35 Shore A to about 55 Shore D.

Not to be limited by theory, the material hardness is believed to behighly correlated with and may be used to specify the desiredstiffness/flexibility of the cleaning element(s) in order to manipulatehow the cleaning element(s) will move (e.g., twisting, bending, and/orother deformation) and how significant this motion will be due to adriving motion provided to the oral care implement. Elastomericmaterials enable the element(s) (e.g., elements 10, 50, 150, 2050) totwist, bend and otherwise deform, providing the element's cleaning edges(e.g., transverse and longitudinal edges) access to the plaque anddebris at the various locations on surfaces of the teeth, including theinterdental areas. (See, for example, FIGS. 24A-F). As set forth herein,the material used for the elements may be flexible enough to twist,bend, and deform in order to permit one or more elements to contact theteeth. However, in certain embodiments, if the element is too flexible,it will lack the rigidity, particularly its edges, to effectively, if atall, remove plaque and debris from the oral cavity surfaces. Thus, insome embodiments, the hardness of the material may also be configured inorder that the stiffness/flexibility of the element(s) is sufficientand/or adequate enough that the cleaning edge (e.g., transverse and/orlongitudinal edges) of the element is able overcome the plaque ordebris' adhesion to the tooth's surface. Thus, some of the embodimentsshown and described herein provide such a balance between the twocompeting factors.

In one embodiment, the material may comprise a thermoplastic elastomer,including but not limited to Pellethane 2363, which is commerciallyavailable from Dow Chemical Company, 4520 Ashman Street, Midland, Mich.48642. In another embodiment, the compliant and/or flexible materialused for the elements and/or base may have the following materialproperties: a hardness (durometer) from about 55 Shore A to about 55Shore D; wet friction greater than about 0.05, particularly greater thanabout 0.1, more particularly greater than or equal to about 0.5 in orderto create friction in the wet oral environment that may be sufficientenough such that the element edges engage the adhesion boundary betweenthe plaque and the surface of the tooth, rather than slide over thesurface of the plaque; surface pressure (contact angle) greater thanabout 500 Nm⁻¹×10⁴, more particularly greater than about 600 Nm⁻¹×10⁴,even more particularly greater than about 700 Nm⁻¹×10⁴, even moreparticularly about 727 Nm⁻¹×10⁴; and density from about 0.05 g/cm³ toabout 3.0 g/cm³, from about 0.5 g/cm³ to about 2.0 g/cm³, moreparticularly 0.9 g/cm³ to about 1.2 g/cm³. One or more of theembodiments of the cleaning implement and its plurality of elementsshown and described herein are configured such that the dislodged plaqueand debris can be transported from the cleaning site with the aid ofsurface wetting and/or capillary action of the saliva, water and/ordentifrice/plaque/debris suspension or slurry.

In one embodiment, the elements (e.g., element 10, 50, 150, 2050, etc.)and base (e.g., bases 100, 200, etc.) are injection molded as oneintegral part with a hydraulic, screw injector, heated barrel, singlecavity, water cooled mold, 55 ton conventional press machine as known toone of ordinary skill in the art. The part is molded with a single shotcycle. However, the process can be adapted to mold more than one partper cycle with a larger press and multiple cavities.

The plurality of elements (e.g., elements 10, 50, 150) and the base(e.g., bases 20, 100) may be fabricated using a molding process,particularly a plastic molding process, including but not limited toplastic injection molding, solution casting, micro-injection molding, orany other conventional or yet-to-be developed methods that do not impartpolymer chain alignment as does a plastic extrusion process and thusfound in extruded elastomeric elements. Injection molded elements areless directional, permitting more deformation in various cleaningmotions and thus providing more degrees of freedom to the cleaningelements and providing greater access of the cleaning element's edges tothe plaque along the surfaces of the teeth, including interdental areas.As set forth above, the plurality of elements and bases may befabricated at two separate components using two separate moldingprocesses, or they may be fabricated using one molding process to form asingle, integral unit. In another embodiment, the plurality of elements(e.g., 10, 50, 150, 2050) and/or bases (e.g., 20, 100, 2100) may notcomprise an extruded material, particularly extruded nylon, but consistof or only comprise elastomeric material that has been plastic injectionmolded to form such elements and/or bases. The nylon and extrusionprocess will not permit the material (e.g., nylon to flow deep enoughinto the corners of the mold cavity to form micro edges as definedherein).

Referring to FIGS. 12-14, an embodiment of a plastic injection moldsystem 220 is shown for illustration purposes only, and not limitation,in conjunction with a plastic injection mold machine 200 for molding oneor more elements 50 and/or a base (e.g., base 100). The plasticinjection mold system 220 may comprise one or more cavity mold plates.In one embodiment, the plastic injection mold system 220 comprises afirst cavity mold plate 230, a second cavity mold plate 240, a thirdcavity mold plate 250, and a fourth cavity mold plate 260. The first,second, third, and fourth cavity mold plates 230, 240, 250, and 260 eachcomprise a plurality of mold cavities 232, 242, 252, and 262,respectively, disposed therein for forming the respective first, second,third, and fourth segments 60, 70, 80, and 90, respectively, of theplurality of elements 50. In other words, when the four cavity moldplates (e.g., 230, 240, 250, 260) are assembled together theirrespective mold cavities (e.g., 232, 242, 252, 262) form the moldcavities for molding the plurality of elements 50 having segments (e.g.,segments 60, 70, 80, 90) corresponding to respective mold cavities(e.g., mold cavities 232, 242, 252, 262, respectively).

As shown, since the desired transverse cross sectional shape of each ofthe segments of the element 50 are triangular-shaped, the respectivemold cavities are each triangular-shaped. The plurality of mold cavities232, 242, 252, and 162 comprise the interior volume necessary to formthe respective segments (e.g., segments 60, 70, 80, 90) to their desiredsize. The mold system 220, i.e., the assembled four cavity mold plates230, 240, 250, and 260, is configured to be positioned within andconnected to the conventional plastic injection mold machine 200. Inthis embodiment, the plastic injection mold machine 200 may comprise anyvariety of conventional plastic injection mold machines that arecommercially available. The plastic injection mold machine 200 maycomprise a cavity side mold plate 202 and a core side mold plate 203.The core side mold plate 203 may comprise an outer core module 204 andan inner core module 206.

As shown in FIG. 12, the first cavity mold plate 230 has first andsecond plate surfaces 231 and 233, respectively. Similarly, the secondcavity mold plate 240 has first and second plate surfaces 241 and 243,respectively, and the third cavity mold plate 250 has first and secondplate surfaces 251 and 253, respectively. The fourth cavity mold platemay include a first plate surface 263. When the cavity mold plates areassembled together in an transverse abutting configuration as shown inFIGS. 12 and 14, each pair of abutting, transverse mold cavity platesform a transverse intersection. For example, when the first platesurface 231 of first mold cavity plate 230 is abutted against the secondplate surface 243 of the second mold cavity plate 240, a secondtransverse intersection 245 is formed as shown in FIG. 14. Similarly,FIG. 14 shows a third transverse intersection 255 is formed at theabutment of the first plate surface 241 of the second mold cavity plate240 with the second plate surface 253 of the third mold cavity plate250, and a fourth transverse intersection 265 is formed at the abutmentof the first plate surface 251 of the third mold cavity plate 250 withthe second plate surface 263 of the fourth mold cavity plate 260.Additionally, a first transverse intersection 235 may be formed betweenor at the abutment of the second plate surface 233 with a surface of thecavity side mold plate 202 (FIG. 14).

Not to be limited by theory, it is believed that as the plastic isinjected into the plurality of mold cavities (e.g., the plurality ofassembled mold cavities 232, 242, 252, and 262) during a plasticinjection molding process, the gas contained within the mold cavities isforced or caused to exit and/or out-gas from the mold cavities throughthe spaces between the mold cavity plates 230, 240, 250, and 260, i.e.,at the transverse intersections 235, 245, 255, and 265 between the moldcavity plates. The spaces between the mold cavity plates 230, 240, 250,and 260 at the respective transverse intersections shown in FIG. 14 areexaggerated for clarity purposes and not meant to be to scale or forlimitation.

As shown in FIG. 14 and set forth above, the gas may exit and/or out-gasat the transverse intersections 235, 245, 255, and 265. Again, not to belimited by theory, it is believed that when the gas exits and/orout-gases from the mold cavities at and along these transverseintersections between the mold cavity plates, the gas pushes and/ordraws the plastic deep into the respective corners of the mold cavityformed by these transverse intersections 235, 245, 255, and 265. In sodoing, the plastic injection molding process is able to form micro edgesat and along any intersection between two molding plates. As shown inFIGS. 13 and 14, the mold system 220 forms transverse edges 66, 76, 86,and 96 as micro edges at the respective transverse intersections 235,245, 255, and 265. Such micro edges as shown and defined herein cannotbe formed using known plastic extrusion processes as used to formconventional bristles and flexible elements, particularly bristles andflexible elements used in oral care devices.

Moreover, as set forth above, the conventional plastic injection moldprocesses and mold systems, including but not limited to those shown anddescribed within U.S. Pat. Pub. No. 2009/0007357, cannot form and/orfabricate the micro edges as shown and defined herein. Although U.S.Pat. Pub. No. 2009/0007357 describes its plastic injection mold processand mold systems as forming sharp edges on flexible elements, it hasbeen unexpectedly found that the mold system fabricates micro edgesshown and described herein that include a tip radius that is a wholeorder of magnitude smaller than the tip radii of the sharp edges shownand described in U.S. Pat. Pub. No. 2009/0007357.

In order to form micro edges along the longitudinal edges 68 a-c, 78a-c, 88 a-c, and/or 98 a-c, one or more of the cavity mold plates 230,240, 250, 260 may be divided up into a plurality of longitudinal cavitymold plates, wherein each one may form a row of mold cavities orindividual mold cavities as will be shown and described below withreference to the embodiments. Referring to FIGS. 15 and 16, anotherembodiment of a plastic injection mold system 220 is shown. The plasticinjection mold system 220 comprises a first cavity mold plate 230, asecond cavity mold plate 240, a third cavity mold plate 250, and afourth cavity mold plate 260. In this embodiment, the first cavity moldplate 230 may comprise a plurality of longitudinal cavity mold plates230 a-230 t, wherein each longitudinal cavity mold plate 230 a-tcomprises two longitudinal plate surfaces such as, for example, a firstlongitudinal plate surface 231 a and a second longitudinal plate surface233 a of first longitudinal cavity mold plate 230 a and a firstlongitudinal plate surface 231 b and a second longitudinal plate surface233 b of second longitudinal cavity mold plate 230 b. When the secondlongitudinal plate surface 233 a abuts the first longitudinal platesurface 231 b as shown in FIG. 15A, this intersection forms alongitudinal intersection 236. (See also FIG. 15B). Each consecutivelongitudinal mold plate has similar first and second longitudinal platesurfaces forming their respective longitudinal intersections 236 asshown and described for the first longitudinal cavity mold plate 230 a.In addition, each longitudinal cavity mold plate 230 a-t forms a row ofmold cavities to mold the first segments 60 of the plurality of elements50.

The fourth cavity mold plate 260 also comprises a plurality oflongitudinal cavity mold plates 260 a-t, wherein each longitudinalcavity mold plate 260 a-t comprises two longitudinal plate surfaces suchas, for example, a first longitudinal plate surface 261 a and a secondlongitudinal plate surface (263 a) of first longitudinal cavity moldplate 260 a and a first longitudinal plate surface 261 b and a secondlongitudinal plate surface (263 b) of second longitudinal plate surface260 b. When the second longitudinal plate surface 263 a abuts the firstlongitudinal plate surface 261 b as shown in FIGS. 15A and 15B, thisintersection forms a longitudinal intersection 266. Each consecutivelongitudinal mold plate has similar first and second longitudinal platesurfaces forming their respective longitudinal intersections 266 asshown and described for the first longitudinal cavity mold plate 260 a.Also, a first and second longitudinal end mold plates 267 a and 267 bwhich form respective longitudinal intersections 266 with longitudinalcavity mold plate 260 a and 260 t, respectively, as shown in FIG. 15A.In addition, each longitudinal cavity mold plate 260 a-t forms a row ofmold cavities 262 to mold the fourth segments 90 of the plurality ofelements 50. In this embodiment, the second and third cavity mold plates240 and 250 are each a single mold plate comprising a plurality of moldcavities 242 and 252, respectively, therein to mold the second and thirdsegments 70 and 80, respectively.

The first longitudinal cavity mold plates 230 a-t, second cavity moldplate 240, third cavity mold plate, and fourth longitudinal cavity moldplates 260 a-t may be assembled together and positioned within aconventional plastic injection mold machine (e.g., plastic injectionmold machine 200 shown in FIG. 12). When assembled together, the firstlongitudinal cavity mold plates 230 a-t, second cavity mold plate 240,third cavity mold plate, and fourth longitudinal cavity mold plates 260a-t form respective transverse intersections. For example, the firstlongitudinal cavity mold plates 230 a-t as an assembly form a firsttransverse intersection 235 between the cavity side mold plate 202 andthe plates 230 a-t themselves. At the abutment of the first longitudinalcavity mold plates 230 a-t with the second cavity mold plate 240, asecond transverse intersection 245 is formed. The abutment of the secondcavity mold plate 240 and the third cavity mold plate 250 forms a thirdtransverse intersection 255. Also, the abutment of the third cavity moldplate 250 with the fourth cavity mold plates 260 a-t forms a fourthtransverse intersection 265. Once the cavity mold plates 230 a-t, 240,250, and 260 are assembled together to form the mold system 220, themold system 220 may be disposed within and connected to a conventionalplastic injection mold machine (e.g., similar to or the same as moldmachine 200 shown in FIG. 12). Although not shown, mold machine willcomprise a cavity side mold plate (e.g., cavity side mold plate 202 inFIG. 12) having a first surface.

Not to be limited by theory, it is believed that as the plastic isinjected into the plurality of mold cavities (e.g., the plurality ofassembled mold cavities 232, 242, 252, and 262), the gas containedwithin the mold cavities is forced or caused to exit and/or out-gas fromthe mold cavities between the cavity mold plates 230 a-t, 240, 250,and/or 260 a-t at and along any intersection between the mold plates(i.e., through the spaces between these plates) such as, for example,longitudinal intersections 236 and 266 and/or transverse intersections235, 245, 255, and 265. Again, not to be limited by theory, when the gasexits and/or out-gases from the mold cavities at and along thetransverse and/or longitudinal intersections, the gas pushes and/ordraws the plastic deep into the corners of the mold cavities (e.g., moldcavity corners 262 a and 262 c shown in FIG. 15B). In so doing, theplastic injection molding process is able to form micro edges at andalong any intersection, both transverse and longitudinal, between anytwo molding plates and/or between any mold plate and the cavity sidemold plate 202.

Still referring to FIGS. 15 and 16, the mold system 220 forms transverseedges 66, 76, 86, and 96 of the plurality of elements 50 as micro edgesusing the respective transverse intersections 235, 245, 255, 265. Inaddition, the mold system 220 forms longitudinal edges 68 b, 68 c, 98 a,and 98 c of the plurality of elements 50 as micro edges using therespective longitudinal intersections 236 and 266 between the respectivelongitudinal cavity mold plates 230 a-t and 260 a-t. In this embodiment,micro edges (e.g., transverse and/or longitudinal micro edges) cannot beformed using a plastic extrusion process as used to form conventionalbristles and flexible elements, particularly those used for oral caredevices.

As set forth above, this mold system 220 may be inserted into andconnected to a conventional plastic injection molding machine. Asconfigured in this mold system 220, It is understood that if additionallongitudinal edges were desired, both the second and third cavity moldplates 240 and 250 may also be divided up into longitudinal cavity moldplates as found and shown with the first and fourth cavity mold plates230 a-t and 260 a-t, respectively.

Referring to FIGS. 17-19, another embodiment of a plastic injection moldsystem 520 is shown to form a plurality of elements 155. FIG. 18illustrates one of element 155 that the plurality of elements maycomprise. The plastic injection mold system 520 comprises a first cavitymold plate assembly 530 to form a first segment 60 of the element 155using a plurality of mold cavities 542 a-t, 552 a-t, 562 a-t, 572 a-t582 a-t, 592 a-t, 602 a-t, 612 a-t, 622 a-t, 632 a-t, 642 a-t, 652 a-t,662 a-t, 672 a-t, 682 a-t, 692 a-t, 702 a-t, 712 a-t, 722 a-t, and 732a-t and a second cavity mold plate (not shown) to form a second segment70 of the element 155 using a plurality of mold cavities (not shown).For simplicity and clarity purposes, FIGS. 17, 19A, and 19B only showthe first cavity mold plate assembly 530 of the mold system 520. Inaddition, FIGS. 17, 19A, and 19B show a cavity side mold plate 202 of aconventional plastic injection molding machine (e.g., machine 200 asshown in FIG. 12) in order to illustrate the engagement and connectionof the first cavity mold plate assembly 530 with and to such cavity sidemold plate 202.

As shown and described in the embodiments set forth above herein, thefirst cavity mold plate assembly 530 and the cavity side mold plate 202may form a first transverse intersection 535 as shown in FIG. 19B.Additionally, not to be limited by theory, the first transverseintersection 535 may form a micro edge along transverse edge 66 of theelement 155 shown in FIG. 18 due to the gas exiting and/or out-gassingfrom the plurality of mold cavities as the transverse intersection 535as shown and described above herein with respect to the embodiments.Similarly, not to be limited by theory, a second transverse intersection(not shown) may be formed between the first cavity mold plate assembly530 and the second cavity mold plate (not shown) to form a micro edgealong transverse edge 76 of element 155 as shown in FIG. 18 due to thegas exiting and/or out-gassing from the plurality of mold cavities asthe transverse intersection as shown and described above herein withrespect to the embodiments. It should be understood that secondtransverse intersections may be removed by the first and second segments60 and 70 from a single and/or integral mold plate having an integralmold cavity that forms both segments. As such, the gas cannot exitand/or out-gas at the place within the mold cavity that forms thetransverse edge 76.

As shown in FIGS. 17, 19A, and 19B, the first cavity mold plate assembly530 may comprise a plurality of individual cavity mold plates (e.g.,cavity mold plates 540 a-t, 550 a-t, 560 a-t, 570 a-t, 580 a-t, 590 a-t,600 a-t, 610 a-t, 620 a-t, 630 a-t, 640 a-t, 650 a-t, 660 a-t, 670 a-t,680 a-t, 690 a-t, 700 a-t, 710 a-t, 720 a-t, and 730 a-t), a pluralityof plate separators 547 a-t, and a plurality of end plates 740 a-t. Thecavity mold plates and plate separators form a plurality of moldcavities. For example, the cavity mold plates 540 a-t and plateseparator 547 a form a plurality of mold cavities 542 a-t, the cavitymold plates 550 a-t and plate separator 547 b form a plurality of moldcavities 552 a-t, the cavity mold plates 560 a-t and plate separator 547c form a plurality of mold cavities 562 a-t, and so on through thecavity mold plates 730 a-t, wherein the cavity mold plates 730 a-t andplate separator 547 t form a plurality of mold cavities 732 a-t.

When assembled, the cavity mold plates (e.g., cavity mold plates 540a-t, 550 a-t, 560 a-t, 570 a-t, 580 a-t, 590 a-t, 600 a-t, 610 a-t, 620a-t, 630 a-t, 640 a-t, 650 a-t, 660 a-t, 670 a-t, 680 a-t, 690 a-t, 700a-t, 710 a-t, 720 a-t, and 730 a-t) and the plate separators 547 a-tform a plurality of first and second longitudinal intersections betweenthese cavity mold plates and the plate separators. As examples, a firstlongitudinal intersection 737 a is formed between cavity mold plate 730a and plate separator 547 t, and a second longitudinal intersection 736a may be formed between the cavity mold plate 730 b and plate separator547 t as shown in FIG. 19B. Not to be limited by theory, these twolongitudinal intersections may form micro edges along longitudinal edges68 b and 68 c respectively of mold cavity 732 a due to the gas exitingand/or out-gassing through the respective intersections during theplastic injection molding process. As another example, a firstlongitudinal intersection 737 e may be formed between cavity mold plate730 e and plate separator 547 t, and a second longitudinal intersection736 e may be formed between the cavity mold plate 730 f and plateseparator 547 t as shown in FIGS. 17, 19A, and 19B. Again, not to belimited by theory, these two longitudinal intersections may form microedges along longitudinal edges 68 b and 68 c respectively of mold cavity732 e due to the gas exiting and/or out-gassing through the respectiveintersections during the plastic injection molding process.

A plurality of third longitudinal intersections may be formed between(i.e., the abutment of) adjacent cavity mold plates 540 a-t, 550 a-t,560 a-t, 570 a-t, 580 a-t, 590 a-t, 600 a-t, 610 a-t, 620 a-t, 630 a-t,640 a-t, 650 a-t, 660 a-t, 670 a-t, 680 a-t, 690 a-t, 700 a-t, 710 a-t,720 a-t, and 730 a-t. As an example, a third longitudinal intersection735 a may be formed between adjacent cavity mold plates 730 a and 730 b.Again, not to be limited by theory, this third longitudinal intersection735 a may form a micro edge along the longitudinal edge 68 a of moldcavity 732 a due to the gas exiting and/or out-gassing through thisintersection during the plastic injection molding process. As anotherexample, another third longitudinal intersection may be formed betweenadjacent cavity mold plates 730 e and 730 f. Moreover, not to be limitedby theory, this third longitudinal intersection 735 e may form a microedge along the longitudinal edge 68 a of mold cavity 732 e due to thegas exiting and/or out-gassing through this intersection during theplastic injection molding process.

With this configuration, each of the plurality of mold cavities 542 a-t,552 a-t, 562 a-t, 572 a-t, 582 a-t, 592 a-t, 602 a-t, 612 a-t, 622 a-t,632 a-t, 642 a-t, 652 a-t, 662 a-t, 672 a-t, 682 a-t, 692 a-t, 702 a-t,712 a-t, 722 a-t, and 732 a-t may form a segment of an element 155having three longitudinal intersections (e.g., 735 e, 736 e, and 737 e)that permit the formation of three longitudinal edges 68 a, 68 b, and 68c that comprise micro edges as shown and described herein. It isunderstood that a longitudinal intersection may be formed at each andevery abutment of a cavity mold plate 540 a-t, 550 a-t, 560 a-t, 570a-t, 580 a-t, 590 a-t, 600 a-t, 610 a-t, 620 a-t, 630 a-t, 640 a-t, 650a-t, 660 a-t, 670 a-t, 680 a-t, 690 a-t, 700 a-t, 710 a-t, 720 a-t, and730 a-t with a plate separator 547 a-t and between each and everyadjacent cavity mold plate as shown in FIGS. 17 and 19.

In the embodiment shown in FIGS. 17-19, when the gas exits/out-gasesfrom the mold cavities at and along these transverse and longitudinalintersections between the cavity mold plates, the gas pushes and/ordraws the plastic deep into the corners. In so doing, the moldingprocess of this mold system is able to form micro edges at and along anyintersection, both transverse and longitudinal, between two cavity moldplates and/or assemblies, cavity mold plates/assemblies and plateseparators, adjacent mold plates, cavity mold plates/assemblies and moldmachine surfaces (e.g., cavity side mold plate 202), and/or anycombinations thereof.

It is understood that if additional longitudinal edges were desired onboth segments 60 and 70, the second cavity mold plate 730 could bedivided up into individual cavity mold plates as the first cavity moldplate included, thus forming transverse edges 66 and 76 and longitudinaledges 68 a, 68 b, 68 c, 78 a, 78 b, and 78 c as micro edges. It is alsounderstood that this mold system may be configured to mold any number ofsegments for the element 50 by adding or subtracting the number ofcavity mold plate layers, i.e., if four segments desired, the moldsystem 520 will include four cavity mold plates. It is also understoodthat each cavity mold plate layer may comprise the individual cavitymold plates, plate separators, and other components as shown anddescribed above here as well as other relevant modifications. Inaddition, although a triangular-shaped transverse cross section wasshown in the embodiments shown and described above, any transverse crosssectional shape may be used, including different transverse crosssectional shapes for each segment of an element.

Referring to FIGS. 20 and 21, another embodiment of a plastic moldsystem 1020 and elements 1050 that may be molded using such plastic moldsystem 1020 are shown. The several embodiments of the mold system 1020may be used with a conventional plastic injection mold machine as shownand described above herein and known to one of ordinary skill in the art(e.g., mold machine 200 shown in FIG. 12). In one embodiment, the moldsystem 1020 may comprise a plurality of cavity mold plates (e.g., cavitymold plates 1080, 1090, 1100, 1110, 1120, etc.) that are disposedside-by-side in an orientation that is along a longitudinal axis B-B′rather than having the cavity mold plates position upon each other in anorientation transverse to the longitudinal axis B-B′ such as, forexample, the first, second, third, and fourth cavity mold plates 230,240, 250, and 260 of the mold system shown in

FIGS. 12-14. In the configuration shown in FIGS. 20 and 21, the moldsystem 1020 would form longitudinal intersections (e.g., longitudinalintersections 1081, 1091, 1101, 1111, etc.) between each of the cavitymold plates (e.g., cavity mold plates 1080, 1090, 1100, 1110, 1120,etc.). As shown in FIG. 20, the mold plates 1080, 1090, 1100, 1110,1120, etc., are operable to mold a plurality of elements 1050 using aplurality of mold cavities 1082.

As shown in FIG. 20, elements 1050 each comprise longitudinal edges 1068a, 1068 b, and 1068 c. Referring specifically to FIG. 21, thelongitudinal edge 1068 a is formed by an internal corner 1083 a of themold cavity 1082. Thus, not to be limited by theory, the longitudinaledge 1068 a may not be a micro edge as defined herein because the gaswithin the mold cavity 1082 may not exit and/or out-gas through thisinternal corner 1083 a because this corner does not comprise anintersection between to mold plates. The longitudinal edge 1068 a maycomprise a non-out-gassed edge. A “non-out-gassed” edge is an edge ofthe flexible element that is formed within a single cavity mold plate,i.e., an internal corner within a single mold plate and thus an edge notformed along an intersection of two molding plates, used in a moldingprocess such as plastic injection molding. In other words, anon-out-gassed edge is an edge formed without using out-gassing betweenand through the intersection of two molding plates. In contrast, thelongitudinal edges 1068 b and 1068 c are formed by mold cavity corners1083 b and 1083 c which are formed by a longitudinal intersectionbetween two cavity mold plates (e.g., cavity mold plate 1080 andadjacent cavity mold plate (not shown)). Thus, the longitudinal edges1068 b and 1068 c may be formed as micro edges as defined here.

In one embodiment, a molding cycle for a plurality of cleaning elementsand a base unit fabricated from a Pellethane 2363 resin comprises abarrel temperature of from about 380 degrees F. to about 410 degrees F.,a mold temperature of from about 60 degrees F. to about 140 degrees F.,and an injection pressure of from about 1600 bar to about 1800 bar.

Referring to FIG. 22, an embodiment of an oral care system 2000 isshown, which may comprise an oral care implement 2001 having a base2100, a plurality of flexible, elastomeric elements 2050 extending fromthe base 2100, and a drive system operable to drive, move, and/or pushthe plurality of flexible, elastomeric elements 2050 and/or the base2100 such that the plurality of elements 2050 engage teeth 2020 and/orgums 2010 disposed within an oral cavity (e.g., a human mouth). In oneembodiment, the plurality of elements 2050, the base 2100, and at leasta portion of the drive system is configured to insert into an oralcavity and be positioned adjacent teeth 2020 and gums 2010 of the oralcavity. The oral care system 2000 may further comprise a housing 2120.The base 2100 and plurality of elements 2050 may comprise any of theembodiments shown and described above herein.

As shown in FIG. 22, the drive system may comprise bladder 2110positioned on a side of the base 2100 opposite the plurality of elements2050. The bladder 2110 may comprise a reservoir 2112 for receiving afluid and be flexible such that the bladder may expand and contract inresponse to fluid filling or emptying from the reservoir 2112. Examplesof the flexible materials that the bladder may be fabricated from mayinclude, but not be limited to natural rubber and other sulfurvulcanizable rubbers such as butyl, nitrile, styrene-butediene,saturated rubbers such as silicone, ethylene propylene andepichlorohydrin and thermoplastic elastomers such as polyurethane,polyolefin and styrenic block copolymers. The drive system may alsocomprise a pump 2130 for supplying a fluid from a fluid source (notshown), a conduit 2114 connecting the pump 2130 to the bladder 2110,and/or a motor 2140 for driving the pump. The pump 2130, conduit 2114,and motor 2140 may comprise any conventional or yet-to-be developedpumps, conduits, and/or motors, particularly such devices that are usedfor oral care systems. The conduit 2114 may comprise rigid or semi rigidpiping or flexible hosing as known to one of ordinary skill in the art.

The oral care system 2000 may pump a variety of known or yet-to-bedeveloped fluids into the bladder 2110 from the fluid source, includingbut not limited to water, air, gases, any combinations thereof, andother fluids operable to drive the bladder. The source may be areservoir, the atmosphere, compressed gas tank, or any otherconventional fluid supply. The motor 2140 may be a conventional oryet-to-be developed motor, including but not limited to an electric(both D/C-powered or A/C-powered), magnetic, fuel-powered,manually-powered, electro-chemical, or combinations thereof.

The oral care system 2000 may comprise a housing 2120 that is connectedto or integral to the base 2100. In this embodiment, the bladder 2110 isat least partially encompassed by the base 2100 and the housing 2120.The housing 2120 may be fabricated from a semi-rigid or rigid materialin order to provide a sturdy structure such that when the bladder 2110expands due to the reservoir 2112 filling with fluid, the bladder isforced to expand in the direction shown by arrows (A). Examples of thematerials used to fabricate the housing 2120 may include, but not belimited to plastics, metals, composites, and combinations thereof.Examples of the plastics that may be used for the housing may include,but not be limited to polyacete polyolefin, polyamide andpolyvinylchloride. As the bladder 2110 expands in direction (A) itcauses the elements 2050 to engage the teeth 2020 and gums 2010(“Impact”). The drive system may be reversed as well to cause the base2100 and/or the elements 2050 to move away from the teeth 2020 and gums2010 as illustrated by arrows (B). As such, the pump 2130 may draw thefluid from the reservoir 2112 of the bladder 2110, causing the bladder2110 to contract and thus cause the elements 2050 to move away from theteeth 2020 and gums 2010 (“Lift-off”). The bladder 2110 may comprise apressure from about 0 kPa to about 60 kPa, particularly from about 10kPa to about 40 kPa, or more particularly about 20 kPa. Also, thepressure the elements apply to the teeth 2020 and gums 2010 may comprisefrom about 0 kPa to about 60 kPa, particularly from about 10 kPa toabout 40 kPa, or more particularly about 20 kPa.

The drive system may be connected to a controller such as amicro-controller or microprocessor. This controller may be operable tocontrol the motor and/or pump and thus the pumping of fluid into and outof the bladder 2110, causing a reciprocating action of the plurality ofelements 2050 against and away from the teeth as illustrated by arrows(A and B). The frequency of the reciprocation of the bladder 2110 andthus the elements 2050 (e.g., between Lift-off and Impact) may be fromabout 1 Hz to about 100 Hz, more particularly from about 50 Hz to about90 Hz, more particularly from about 65 Hz to about 75 Hz, or moreparticularly about 70 Hz. In one embodiment, the plurality of elements2050 may be moved away from the teeth 2020 and gums 2010 (“Lift off”) adistance from about 0 mm to about 10 mm, particularly from about 0 mm toabout 8 mm, particularly from about 3 mm to about 7 mm, particularlyfrom about 4 mm to about 6 mm, or more particularly from about 0 mm toabout 5 mm. Also, the implements 2050 may be driven back toward theteeth 2020 and gums 2010 (“Impact”) a distance from the teeth 2020 andgums 2010 (“Lift off”) a distance from about 0 mm to about 10 mm,particularly from about 0 mm to about 8 mm, particularly from about 3 mmto about 7 mm, particularly from about 4 mm to about 6 mm, or moreparticularly from about 0 mm to about 5 mm.

In another embodiment, the drive mechanism may comprise more than one ofthe bladder 2110, particularly if desired to drive elements 2050 indifferent directions. In yet another embodiment, the driving mechanismmay cause the plurality of elements 2050 to move along the teeth 2020and gums 2010 as illustrated by arrows (C), i.e., into and out of thefigure and (D), i.e., transverse to arrow (C). The oral care system 2000and one or more drive systems may cause the elements 2050 to move oroscillate in one or more of the directions along arrows (C) and/or (D) adistance from about 0 mm to about 10 mm, particularly from about 0 mm toabout 6 mm, or particularly from about 0 mm to about 4 mm. Instead of afluid pump and bladder, the drive mechanism may comprise a variety ofother conventional and yet-to-be developed drive and/or actuationsystems, including but not limited to ultrasonic drives, vibratingdrives, oscillating drives, electric motors, piezoelectric,electrostrictive, electromagnetic, magnetostrictive, acoustostrictive,photostrictive and/or chemostrictive actuators.

In another embodiment, an oral care implement 3001 shown in FIG. 23 maycomprise a housing 3120 having a first flexible base 3100 a connected tothe housing 3120, a first plurality of elements 3050 a extending fromthe first base, a second flexible base 3100 b connected to the housing3120, a second plurality of elements 3050 b extending from the secondbase, and a bladder 3110 having a reservoir 3112 therewithin. The oralcare implement 3001 is configured to be inserted within an oral cavityand be substantially U-shaped such that the first plurality of elements3050 a and/or first base 3100 a substantially conform and/or surroundall or some portion of teeth 3020 a and/or gums 3010 a disposed alongthe upper jaw and the second plurality of elements 3050 b and/or secondbase 3100 b substantially conform and/or surround all or some portion ofteeth 3020 b and/or gums 3010 b disposed along the lower jawsimultaneously. In such a configuration, the oral care implement 3001 isoperable to clean the teeth 3020 a-b and/or gums 3010 a-b of the upperand lower jaws simultaneously, sequentially, or any combination thereof.It is understood that the oral care implement 3001 may be combined withany variety of oral care systems, including but not limited to theseveral embodiments of the oral care systems shown and described herein(e.g., oral care system 2000).

One or more of the embodiments of the oral care systems (e.g., oral caresystem 2000) may clean oral cavity tissue (i.e., teeth and gums) in atime less than or equal to about 15 seconds/tooth surface, moreparticularly less than or equal to about 10 seconds/tooth surface, evenmore particularly less than or equal to about 5 seconds/tooth surface.

It is also believed, but not intended to be held by theory, that one ormore of the embodiments of the oral care systems shown and describedherein (e.g., oral care system 2000) and/or oral care implements (e.g.,implements 1, 40, 2001) improve interdental (interstitial) cleaning,i.e., cleaning of the teeth and gums disposed between adjacent teeth,compared to conventional oral care cleaning implements and devices.Teeth generally are positioned about 1 mm to about 1.5 mm apart fromeach other. In one or more of the embodiments shown and describedherein, the base (e.g., bases 20, 100, etc.) comprises the plurality ofelements spaced (e.g., tip density) such that approximately 6 to 7elements fit within the space between adjacent teeth (e.g., theapproximately 1 mm to 1.5 mm spacing between teeth) thus providingimproved interdental cleaning.

As an example, FIGS. 24A-F illustrate such oral care implement havingflexible cleaning elements that provide improved interdental cleaningdue to the elements size (e.g., width, length) and oral care implement'selement density as set forth above. FIGS. 24A-F illustrate sequentialframes of an array of flexible elements 3050 having a triangular shape,transverse cross-section as they are moved and/or pushed into aninterdental area 3080 between two teeth 3081 and 3082, respectively.Perspective representations of a view from distal ends 3052 towardproximal ends 3054 of the plurality of flexible elements are shown inFIGS. 24A and 24D, and isometric views are shown in FIGS. 24B and 24C toillustrate an example of the orientation and position of the flexible,elastomeric elements 3050 with respect to the interdental area 3080before and as the plurality of flexible elements 3050 are being movedinto and initially engaging the teeth surfaces within the interdentalarea 3080.

As set forth above and not to be limited by theory, it is believed thatthe cross-sectional size and shape, length, and/or material properties(e.g., material hardness, material wetness, etc.) of the flexibleelement along with the element density of the oral care implement and/orthe type of motion used to drive the plurality of elements can beutilized and maximized to improve the twisting, bending, and/or otherdeformation motion of the flexible elements in order to improve and/ormaximize the engagement of the edges, particularly micro edges, and thecontact stresses with the surfaces of teeth, particularly with thesurfaces within interdental areas. FIG. 24E-F illustrates, as anexample, how such a combination of flexible element and oral careimplement properties can affect the contact stresses and contactengagement of the edges and/or surfaces of the flexible elements onteeth. As shown, adjusting and controlling such properties will alsoimpact how the flexible elements twist, bend, and/or deform when one ormore of the flexible elements fully engage the teeth surfaces within theinterdental area 3080.

FIG. 24F provides an illustrative representation of a view from thedistal ends 3052 toward the proximal ends 3054 shown in FIG. 24E withthe teeth removed from the view. As shown in FIG. 24F, one or more ofthe plurality of flexible elements 3050 twist, bend and/or deform suchthat more than one transverse edge and/or one or more longitudinal edgeare caused to engage the teeth surfaces in the interdental area 3080. Itis understood that one or more transverse edge 3056 and/or one or morelongitudinal edge 3058 may comprise a micro edge as shown and definedherein. FIG. 24E also shows, based upon a finite element analysis, viashading what portion of the flexible elements contact the teeth surfaceswithin the interdental area. The darker shaded areas show the highestlevel of contact stress (CPRESS in figure legend) between the elementand the tooth's surface due to the movement of the element against thetooth. As shown, the configuration in this example provides multipleedges contacting the teeth surfaces (contact trace) with increasedcontact stresses along those edges, thus providing improved interdentalcleaning.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An oral care implement comprising: a base portionsized for insertion into an oral cavity; and a plurality of flexible,elastomeric elements extending from the base portion, wherein: each ofthe plurality of flexible, elastomeric elements comprises an edge, atleast one of the edges comprises a micro edge, and the plurality offlexible, elastomeric elements comprises an element density of less thanabout 5 mm.
 2. The oral care implement of claim 1, wherein the elementdensity is from about 0.1 mm to about 3.0 mm.
 3. The oral care implementof claim 2, wherein the element density is from about 0.1 to about 2.0mm.
 4. The oral care implement of claim 1, wherein the micro edgecomprises a tip radius (R) that is less than 0.02 mm.
 5. The oral careimplement of claim 4, wherein the micro edge comprises a tip radius (R)that is less than or equal to about 0.015 mm.
 6. The oral care implementof claim 1, wherein the micro edge comprises a tip radius (R) that isfrom about 0.015 mm to about 0.0015 mm.
 7. The oral care implement ofclaim 1, wherein at least one of the edges comprises an out-gassed edge.8. The oral care implement of claim 1, wherein the plurality offlexible, elastomeric elements are not extruded elastomeric elements. 9.The oral care implement of claim 1, wherein the plurality of flexible,elastomeric elements comprise a material having a Shore Hardness of fromabout 8 Shore A to about 75 Shore D.
 10. The oral care implement ofclaim 9, wherein the plurality of flexible, elastomeric elementscomprise a material comprising a Shore Hardness of from about 35 Shore Ato about 55 Shore D.
 11. The oral care implement of claim 10, whereinthe material further comprises a wet friction greater than about 0.05.12. The oral care implement of claim 11, wherein the plurality offlexible, elastomeric elements have a length from about 0.05 mm to about10 mm.
 13. The oral care implement of claim 12, wherein the lengthcomprises from about 2.0 mm to about 6 mm.
 14. The oral care implementof claim 11, wherein the material further comprises: a hardness fromabout 55 Shore A to about 55 Shore D, a wet friction greater than about0.1, a surface tension greater than about 500 Nm⁻¹×10⁴, and a materialdensity from about 0.05 g/cm³ to about 3.0 g/cm³.
 15. The oral caresystem of claim 14, wherein the surface tension is greater than about600 Nm⁻¹×10⁴ and the material density is from about 0.5 g/cm³ to about2.0 g/cm³.
 16. An oral care implement comprising: a base portion sizedfor insertion into an oral cavity; and a plurality of flexible,elastomeric elements extending from the base portion; wherein at leastone of the plurality of flexible, elastomeric elements comprises a firstsection having a first section edge and a first transverse crosssectional area, and a second section disposed adjacent to the firstsection along a longitudinal axis of the at least one of the pluralityof flexible, elastomeric elements, the second section having a secondsection edge and a second transverse cross sectional area different fromthe first transverse cross sectional area.
 17. The oral care implementof claim 16, wherein the second transverse cross sectional area is lessthan the first transverse cross sectional area.
 18. The oral careimplement of claim 16, wherein: the first transverse cross sectionalarea has a first shape; the second transverse cross sectional area has asecond shape; and the first shape is different from the second shape.19. The oral care implement of claim 16, wherein the at least one of theplurality of flexible, elastomeric elements further comprises a thirdsection having a third transverse cross sectional area that is disposedadjacent to the second section along the longitudinal axis, and whereinthe third transverse cross sectional area is different than the firstand second transverse cross sectional areas.
 20. The oral care implementof claim 19, wherein the third transverse cross sectional area is lessthan the first and second transverse cross sectional areas.
 21. The oralcare implement of claim 19, wherein the at least one of the plurality offlexible, elastomeric elements further comprises a fourth section havinga fourth transverse cross sectional area that is disposed adjacent tothe third section along the longitudinal axis of the at least one of theplurality of flexible, elastomeric elements, and wherein the fourthtransverse cross sectional area is different than the first, second, andthird transverse cross sectional areas.
 22. The oral care implement ofclaim 21, wherein the third transverse cross sectional area is less thanthe first and second transverse cross sectional areas and the fourthtransverse cross sectional area is less than the first, second, andthird transverse cross sectional areas.
 23. The oral care implement ofclaim 16, wherein the first and second section edges comprise a tipradius (R) that is less than 0.0254 mm.
 24. The oral care implement ofclaim 23, wherein the first and second section edges comprise a tipradius (R) that is less than or equal to about 0.015 mm.
 25. The oralcare implement of claim 24, wherein the first and second section edgescomprise a tip radius (R) that is from about 0.015 mm to about 0.0015mm.
 26. The oral care implement of claim 14, wherein the plurality offlexible elements are disposed on the base portion such that the baseportion comprises an element density from about 0.1 to about 3.0 mm. 27.The oral care implement of claim 16, wherein the first and secondsection edges comprise out-gassed edges.
 28. The oral care implement ofclaim 16, wherein the first and second section edges are transverseedges.
 29. The oral care implement of claim 28, wherein the secondsection further comprises a longitudinal edge.
 30. The oral careimplement of claim 16, wherein the first and second section edges arelongitudinal edges.
 31. The oral care implement of claim 16, wherein thebase portion is substantially U-shaped such that upon insertion into ahuman mouth, the plurality of flexible, elastomeric elements areadjacent to surfaces of teeth within the mouth.
 32. The oral careimplement of claim 16, further comprising a drive mechanism connected tothe base for driving the plurality of flexible, elastomeric elementsinto engagement with the teeth and/or gums within an oral cavity. 33.The oral care implement of claim 32, wherein the drive mechanismselected from the group consisting of a bladder, ultrasonic drive,vibrating drive, oscillating drive, electric motor, piezoelectricactuator, electrostrictive actuator, electromagnetic actuator,magnetostrictive actuator, acoustostrictive actuator, photostrictiveactuator, and chemostrictive actuator.
 34. The oral care implement ofclaim 32, wherein the drive mechanism comprises a bladder connected to aside of the base portion opposite the plurality of flexible, elastomericelements.
 35. The oral care implement of claim 34, further comprising afluid source in fluid communication with an interior chamber of thebladder for providing a fluid to the bladder.
 36. The oral careimplement of claim 35, wherein the fluid source comprises a pump and avacuum for pumping fluid to the bladder and for evacuating the fluidfrom the bladder.
 37. An oral care implement comprising: a base portionsized for insertion into an oral cavity, the base portion having a basewall and two opposed, side walls connected to the base wall that form achannel for receiving teeth within an oral cavity; and a plurality offlexible, elastomeric elements extending into the channel from the baseand two opposed, side walls, wherein: each of the plurality of flexible,elastomeric elements comprises an edge and a longitudinal axis, at leastone of the plurality of flexible, elastomeric elements comprises a firstsection having a first transverse cross sectional area and a secondsection having a second transverse cross sectional area that is disposedadjacent to the first section along the longitudinal axis of the atleast one flexible, elastomeric element, and the second transverse crosssectional area is different than the first transverse cross sectionalarea.
 38. A method of forming a micro edge of an flexible, elastomericelement, the method comprising: forming a mold cavity with a first moldplate and a second mold plate positioned adjacent to the first moldplate; forming a mold corner of the mold cavity using an intersection ofthe first mold plate and second mold plate; injecting an elastomer intothe mold cavity; and allowing gas contained within the mold cavity toout-gas through the intersection between the first and second moldplates to form a micro edge along the mold corner formed by theintersection.
 39. The method of claim 38, wherein the step of forming amold cavity with a first mold plate and a second mold plate positionedadjacent to the first mold plate comprises forming a first mold cavityand a second mold cavity, and wherein the step of forming a mold cornerof the mold cavity using an intersection of the first mold plate andsecond mold plate comprises forming a first mold corner of the firstmold cavity and a second mold corner of the second mold corner using theintersection of the first mold plate and second mold plate.
 40. Themethod of claim 39, wherein the step of forming a mold cavity with afirst mold plate and a second mold plate positioned adjacent to thefirst mold plate comprises forming a plurality of mold cavities with afirst mold plate and a second mold plate adjacent to the first moldplate, and wherein the step of forming a mold corner of the mold cavityusing an intersection of the first mold plate and second mold platecomprises forming a mold corner for each of the plurality mold cavitiesusing the intersection of the first mold plate and second mold plate.41. The method of claim 38, wherein the step of forming a mold corner ofthe mold cavity using an intersection of the first mold plate and secondmold plate comprises forming a first corner and a second corner of themold cavity using an intersection of the first mold plate and the secondmold plate.
 42. The method of claim 38, wherein the step of forming amold cavity with a first mold plate and a second mold plate positionedadjacent to the first mold plate forming a plurality of mold cavitieswith a first mold plate and a plurality of mold plates adjacent to thefirst mold plate, and wherein the step of forming a mold corner of themold cavity using an intersection of the first mold plate and secondmold plate comprises forming a plurality of mold corners of theplurality of mold cavities using a plurality of intersections of thefirst mold plate and the plurality of mold plates.
 43. The method of 42,wherein the step of forming a mold corner of the mold cavity using anintersection of the first mold plate and second mold plate furthercomprises forming a plurality of mold corners of the plurality of moldcavities using a plurality of intersections between the plurality ofmold plates or of the plurality of mold plates and a plurality of moldseparators.
 44. The method of 38, further comprising: forming the moldcavity with a third mold plate positioned adjacent to the second moldplate; forming a second mold corner of the mold cavity using a secondintersection of the second mold plate and third mold plate; and allowinggas contained within the mold cavity to out-gas through the secondintersection between the second and third mold plates to form a secondmicro edge along the second mold corner formed by the secondintersection.
 45. The method of 44, further comprising: forming the moldcavity with a fourth mold plate positioned adjacent to the third moldplate; forming a third mold corner of the mold cavity using a thirdintersection of the third mold plate and fourth mold plate; and allowinggas contained within the mold cavity to out-gas through the thirdintersection between the third and fourth mold plates to form a thirdmicro edge along the third mold corner formed by the third intersection.46. The method of 45, wherein the first mold plate comprises a firstplurality of longitudinal cavity mold plates assembled adjacent oneanother for forming a plurality of longitudinal mold corners usingintersections between adjacent longitudinal cavity mold plates of thefirst plurality of longitudinal cavity mold plates.
 47. The method of46, wherein the fourth mold plate comprise a second plurality oflongitudinal cavity mold plates adjacent one another for forming aplurality of longitudinal mold corners using intersections betweenadjacent longitudinal cavity mold plates of the second plurality oflongitudinal cavity mold plates.
 48. The method of claim 38, wherein theintersection is a transverse intersection formed between the first andsecond mold plates.
 49. The method of claim 38, wherein the intersectionis a longitudinal intersection formed between the first and second moldplates.